HP Plotter Repair
So after I found the bad driver chips and blown surface mount fuses, and before I got the manual, (which does not have circuit diagrams anyway), I replaced the drivers a few times and finally traced out the driver circuit back to the ink service station elevator motor.
(drivers are split over two driver chips for one motor)

About the time I ohmed out the shorted motor, I got the manual.

"If you replace the electronics module without replacing the bad motor,
the electronics module will blow again..."
  duh.


I figured out that the printer powers up and self tests each motor by sending a quick pulse and measuring the current drawn. If the motor's coil resistance is wrong, the test stops and tells the operator that there is something wrong. Rather than say "I think there is a failure in the ink service station motor, call for service",     it says something like "err 917263876 or 63738292"

Very helpful HP. Have another Guiness.

What really happens is that the self test may or may not pass if your motor has a few shorted turns, if it fails the test you get the error, If it passes the CPU continues to boot (several minutes) then the motors are initiallized (homed) and when one of the motors is shorted, it blows the driver.

Because HP engineers spread the motor drives for a single motor over several driver chips, (presumabily to help with heat dissipation), the bad motor blows the driver chip but the self test can't test the other motor that the driver runs so the diagnostic indicates the wrong motor is bad. You go check the supposedly bad motor's resistance and it's OK.

It was only after I traced the lines from the driver to the elevator motor that I found the problem. And then of course it was a special motor that could not be found anywhere.

motor resistance table.JPG
motor resistance table.JPG

HP parts list.JPG
HP parts list.JPG
$400 bucks ! for the ink service module. - stepper custom for HP and none on Ebay - what should I do ?


Open it up and figure it out, what else?

motor-cover rremoved.JPG
motor-cover removed.JPG

toasted coil.JPG
toasted coil.JPG

toasted wire on floor.JPG
The toasted wire on the floor. Looks like 34ga by my caliper
All I have is 30ga...
I wonder it it will fit and give me the resistance I need?

coil rewound w spindle.JPG
Here's the coil rewound (1st time), 30GA w spindle - 30ga is too big.
Time to buy some 34ga on Ebay

30GA wire removed.JPG
30GA wire removed........

coils rewound on scale2.JPG
coils rewound on scale2.JPG

coils close up.JPG
coils close up.JPG

coil termination.JPG
coil termination.JPG

motor assembled.JPG
motor assembled.JPG

test ckt and pic programmer.JPG
test ckt and pic programmer.JPG

test circuit and motor.JPG
I brewed up this test circuit to run the motor before replacing the "no user servicable parts inside" motor.
(Guess it depends on the user)

The little board in the vice is my way to jump the wires around to get the rotation direction that I think will work in the printer.